Process for the manufacturing of a decorative thermo-setting plastic laminate

ABSTRACT

Process for the manufacturing of a decorative thermosetting laminate with a wear-resistant and a scratch resistant surface layer, wherein a continuous paper web is impregnated with melamine-formaldehyde resin, that one side of the web is coated with hard particles with a size of 30-90 μm. After drying, the other side is coated with a melamine-formaldehyde resin containing hard particles with an average particle size of 1-15 μm. The paper is, after drying, placed as the uppermost sheet in a laminate with the side coated with the smallest particles directed upwards towards a continuous pressure surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a process for the manufacturing of adecorative thermosetting laminate with an abrasion and scratch resistantsurface layer.

2. Description of the Related Art

Decorative thermosetting laminates are well known and used for instanceas surface material for walls, cupboard doors, desktops, tabletops, forother furniture and as a flooring material.

Such laminates are often made of two to seven Kraft paper sheetsimpregnated with phenol-formaldehyde resin, a monochromatic or patterneddecor paper sheet impregnated with melamine-formaldehyde resin and afine so called overlay sheet of α-cellulose impregnated withmelamine-formaldehyde resin.

The overlay sheet is intended to protect the decor paper sheet fromabrasion. In certain cases the overlay sheet is omitted.

There are also laminates consisting of a base layer of particle board orfibre board provided with such a decor paper sheet and possible anoverlay sheet. These sheets can be laminated towards the base layerunder heat and pressure. If only a decor paper sheet is used then thiscan be glued towards the base layer.

The described laminates do have many good properties, it has howeverturned out that there is a great need of improving the abrasionresistance and the surface scratch resistance of laminates exposed to anextreme abrasion. This is especially the case for flooring laminates,but to a certain extent also for desktop and tabletop laminates.

According to the U.S. Pat. No. 4,940,503 the abrasion resistance of suchlaminates has successfully been improved. Then a paper web isimpregnated with melamine-formaldehyde resin. At least one side of theweb is coated with small dry and hard particles with an average particlesize of about 1-80 μm, evenly distributed over the wet resin surface onthe web whereafter the resin is dried. The particle coated web, socalled prepreg is thereafter possibly cut into sheets. At least one suchsheet or web is placed as a surface layer on a base layer and bondedthereto. The hereby produced laminate will have a good abrasionresistance.

The hard particles used according to the prior art normally have anaverage particle size of around 50 μm, which is an advantage from anabrasion point of view. It has, however turned out that the scratchresistance of laminates produced in the known way is not alwayssatisfactory. Furthermore the press plates used during the laminatingstage are scratched by the relatively big particles in the surface ofthe laminate. The press plates are very expensive and manufactured of ahigh quality steel. Intermediate layers of disposable aluminium foil areoften used to protect these press plates which will affect theproduction cost.

There is a need to be able to produce an abrasion and scratch resistantdecorative laminate and to avoid the above mentioned problems.

SUMMARY OF THE INVENTION

It has according to the present invention been possible to achieve aprocess for the manufacturing of a decorative thermosetting laminatewith an abrasion and scratch resistant surface layer, which laminatecomprises paper sheets impregnated with thermosetting resin. The processis characterised in that a first continuous paper web is impregnatedwith melamine-formaldehyde resin, that one side of the first web iscoated with about 2-20 g/m², preferably about 6-12 g/m² of hardparticles with an average particle size of about 30-90 μm, preferablyaround 40-70 μm. The particles are evenly distributed over the whole wetresin surface of the first paper web, after which the resin is dried.The other side of the web, or a second paper web is coated with amelamine-formaldehyde resin, where the resin contains hard particleswith an average particle size of about 1-15 μm, preferably about 1-9 μmand in such an amount that the web will have a coating of about 1-15g/m², preferably about 2-10 g/m² of these hard particles, whereafter theresin is dried. The particle-coated impregnated first paper web, a socalled prepreg, is possibly cut into sheets. At least one of thesepossibly cut sheets of paper or web is placed as a surface layer on abase layer and bonded thereto whereby the surface coated with thesmaller particles is placed so that it is directed towards the upperside of the laminate and the surface with the bigger particles isdirected downwards. Alternatively the first sheet or web with thesmaller particles is placed as the uppermost layer in the laminate withthe particle coated side directed towards the upper side of the laminateand the second sheet or web with the bigger particles is placed underthe uppermost layer with the particle-coated surface directed outwards.

The hard particles can consists of many different materials. Especiallysuitable materials are silicon dioxide, aluminium oxide, and/or siliconcarbide. A blend between two or more materials is accordingly alsopossible.

The base layer can consists of a fibre-board or a particle-board,whereby the particle coated paper sheet is bonded to the base layer bylaminating under heat and pressure or by gluing. The base layer can alsoconsist of a number of conventional dry pre-preg webs or prepreg sheetsrespectively which are not coated with particles. The particle coatedweb or sheet respectively is placed on top of these conventional webs orsheets, whereby the resin in the uppermost of these webs respectivelysheets normally consists of melamine-formaldehyde resin, while the restof the webs respectively sheets preferably contains phenol-formaldehyderesin or phenol-urea formaldehyde resin, whereafter the websrespectively a stack of sheets continuously respectively discontinuouslyare laminated together with the surface layer by using a high pressureand an increased temperature.

The particle coated paper web or paper sheet often consists of aso-called overlay paper, preferably of α-cellulose.

It is, however also possible to coat the so-called decorative sheet withthe hard particles. The decorative sheet can be patterned ormonochromatic.

In some cases it is possible to coat the overlay sheet as well as thedecorative sheet with particles or use two ore more particle coatedoverlay sheets or decorative sheets. It is also possible to place aconventional not particle coated overlay sheet on top of the particlecoated sheet or sheets.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a device comprising a container 1 in which small hardparticles 2 are distributed on a rotating doctor-roll 3 with an unevensurface placed under the container whereby the hard particles 2 falldown from the container 1 to the doctor-roll 3 and then be evenlydistributed on a paper web 4 continuously fed under doctor-roll 3according to U.S. Pat. No. 4,940,503. The device often comprises ascraper plate 5 and an air knife 6 or the like to help the hardparticles 2 come loose from the doctor-roll 3 at a constant amount perunit of time. The device can also comprise a tightening brush 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBEDMENTS

The invention will be explained further in connection to the embodimentexamples below, of which the examples 1-7 illustrates a first embodimentof the invention where the uppermost sheet in the laminate consists of aso-called overlay on the top side coated with a slurry ofmelamine-formaldehyde resin containing small hard particles, and on thelower sides coated with somewhat larger particles in the still wetmelamine-formaldehyde resin which the paper has been impregnated with.

Example 8 represents a prior art laminate for comparison, which laminatewas made in accordance with the U.S. Pat. No. 4,940,503 where theuppermost sheet in the laminate has been coated with rather bigparticles on the lower side in still wet melamine-formaldehyde resinwhich the paper has been impregnated with.

Examples 9 and 10 represent another embodiment of the invention wherethe uppermost sheet in the laminate is coated with a slurry ofmelamine-formaldehyde resin containing small hard particles. The lowerside of this uppermost sheet is not coated with any particles. Insteadsomewhat bigger particles have been sprinkled on the still wet resin onthe top side of the second uppermost melamine-formaldehyde resinimpregnated paper sheet.

Example 11 represents a comparison test outside the scope of theinvention. The uppermost sheet in the laminate consists of an overlaywhich on the top side has been coated with a slurry ofmelamine-formaldehyde resin containing small hard particles. The lowerside of this paper sheet is not coated with any bigger hard particles,nor is there any second underlying sheet coated with bigger hardparticles.

From the examples 1-7 and 9 and 10 according to the invention is itshown that a very good scratch resistance is achieved by the use of thesmall hard particles on the upper side of the uppermost sheet. Thesomewhat bigger particles on the lower side of the uppermost sheet or onthe top side of the following sheet give a very good abrasionresistance.

The comparative test according to example 8 shows that a good abrasionresistance is achieved when bigger hard particles are used on the lowerside of the uppermost sheet. The scratch resistance will however berather poor.

The comparative test according to example 11 shows that a good scratchresistance is achieved when small hard particles is used on the top sideof the uppermost sheet. The abrasion resistance will however be verypoor if the bigger particles are left out on the lower side of theuppermost paper or on underlying paper.

The examples show the measured scratch resistance, measured by means oftwo different methods according to a modified version of ASTMD-2197. Atthe first method the sample is judged in a viewing cupboard at aneye--sample distance of 772-914 mm and at an observation angle between45 and 75 degrees from the table surface. The sample is judged accordinga classification scale. This first method is called distance.

The second method is performed in the same way. The person who makes thetest does however decide the angle and the distance himself so that thereal scratch becomes visible. This second method is called real. A lowvalue indicates the best scratch resistance.

In the examples the scratch resistance has only been measured byscratching across the manufacturing direction of the laminate (paper),since a scratch becomes more visible in this direction. Sometimes alsothe scratch resistance along the laminate is measured.

The abrasion was in the examples measured according to EN 438-2:6.

According to this standard the abrasion through the decorative layer ofthe finished laminates is measured in two steps. In the first step theso-called IP (initial-point) is measured, where the initial abrasionstarts.

In step two the so called EP (end-point) is measured, where 95% of thedecor is worn through.

Additionally the standard prescribes that the number of revolutionsachieved with the testing machine in steps one and two are added andthat the obtained sum is divided by 2. Hereby the 50% point for abrasionis obtained, which normally is the figure reported in standards andoffprints.

In this and the following examples however only the IP is used.

EXAMPLE 1

a) One roll of so called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 57% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 8 g/m². The particles had anaverage size of 50 μm. The particles were applied by using an apparatusas described in the U.S. Pat. No. 4.940,503.

The particle coated paper web was then continuously fed into a heatingoven, where the solvent was evaporated while the resin cured to aso-called B-stage. The moisture content of the paper was after thedrying 10% by weight. The other not sprinkled side of the paper web wascoated with a slurry of melamine-formaldehyde resin containing aluminiumoxide particles to an amount of 5.3% by weight. The average size of theparticles was 1 μm.

The paper web was then continuously dried in an oven until the moisturecontent of the paper was 7% by weight.

The final resin content of the completely impregnated paper was 70% byweight calculated as dry impregnated paper and the total amount of addedaluminium oxide particles was 8+2.7 g/m².

The paper web was cut into sheets of a suitable length.

b) One roll of so called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 70% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 7 g/m² by using the sameapparatus as in a) above. The particles were of an average size of 50μm. The paper web was then dried to a moisture content of 7% by weight.The paper web was cut into sheets of the same length as in a) above.

c) One roll of so called decor paper with a surface weight of 100 g/m²was impregnated with a solution of melamine-formaldehyde resin to aresin content of 46% by weight, calculated on dry impregnated paper. Theimpregnated paper web was dried to a moisture content of 4% by weight.

The paper web was cut into sheets of the same length as in a) and b)above.

d) One roll of Kraft paper with a surface weight of 170 g/m² wasimpregnated with a phenol-formaldehyde resin solution to a resin contentof 28% by weight, calculated on dry impregnated paper. The wet paper webwas dried to a final moisture content of 7% by weight. The paper web wascut into sheets of the same length as above.

The impregnated paper sheets as described in a)-d) above were placedbetween two press plates in the following order; one paper a) with theside with the smallest particles oriented outwards, one paper b) withthe sprinkled side oriented outwards, one paper c) and three papers d).Together the last mentioned papers, so-called base sheets, formed a baselayer in the laminate which was manufactured by pressing of the sheetsin a conventional multi-opening press during 80 minutes and at apressure of 85 bar.

The properties of the manufactured laminate were as follows:

    ______________________________________                                         Abrasion:      16100 revolutions                                             Scratch resistance:                                                                                            across/4 (distance) across/9                 ______________________________________                                                        (real)                                                    

EXAMPLE 2

The procedure according to example 1 was repeated with the differencethat the melamine-formaldehyde slurry in step a) contained aluminiumoxide particles with an average size of 3 μm instead of 1 μm.

The properties of the manufactured laminate were as follows:

    ______________________________________                                         Abrasion:      14050 revolutions                                             Scratch resistance:                                                                                           across/3 (distance), across/3                 ______________________________________                                                        (real)                                                    

EXAMPLE 3

The procedure according to example 1 was repeated with the differencethat the melamine-formaldehyde slurry in step a) contained 10.6% byweight of aluminium oxide particles instead of 5.3% by weight.Additionally the aluminium oxide particles had an average size of 5 μminstead of 1 μm. The total amount of particles was 8+5.4 g/m².

The properties of the manufactured laminate were as follows:

    ______________________________________                                          Abrasion:     15500 revolutions                                             Scratch resistance:                                                                                            cross/1 (distance), cross/7                  ______________________________________                                                        (real)                                                    

EXAMPLE 4

The procedure according to example 3 was repeated with the differencethat the melamine-formaldehyde slurry in step a) contained 15.9% byweight of aluminium oxide particles instead of 10.6% by weight. Also inthis example the aluminium oxide particles had an average size of 5 μm.The total amount of particles added was 8+8.1 g/m².

The properties of the manufactured laminate were as follows:

    ______________________________________                                         Abrasion:      14200 revolutions                                             Scratch resistance:                                                                                           across/1 (distance), across/1                 ______________________________________                                                        (real)                                                    

EXAMPLE 5

The procedure according to example 1 was repeated with the differencethat the melamine-formaldehyde slurry in step a) contained aluminiumoxide particles with an average size of 9 μm instead of 1 μm.

The properties of the manufactured laminate were as follows:

    ______________________________________                                          Abrasion:                     15100 revolutions                             Scratch resistance:                                                                                           across/3 (distance), across/3                 ______________________________________                                                        (real)                                                    

EXAMPLE 6

a) One roll of so called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 57% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 9 g/m². The particles were ofan average size of 50 μm. The particles were applied by using anapparatus as described in the U.S. Pat. No. 4,940,503.

The particle sprinkled paper web was then continuously feed into aheating oven, where the solvent was evaporated while the resin cured toa so-called B-stage. The moisture content of the paper was after drying10% by weight.

The other, not sprinkled side of the paper web was coated with a slurryof melamine-formaldehyde containing aluminium oxide particles to anamount of 10.6% by weight. The average size of the particles was 3 μm.

The paper web was then continuously dried in an oven until the moisturecontent of the paper was 7% by weight.

The final resin content in the completely impregnated paper was 72% byweight calculated as dry impregnated paper, and the total amount ofadded aluminium oxide particles was 9+5.4 g/m².

b) One roll of so-called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 72% by weight, calculated on dryimpregnated paper. The paper web was then dried to a moisture content of7% by weight.

c) One roll of so called decor paper with a surface weight of 100 g/m²was impregnated with a melamine-formaldehyde resin solution to a resincontent of 46% by weight, calculated on dry impregnated paper. Theimpregnated paper web was dried to a moisture content of 4% by weight.

d) One roll of Kraft paper with a surface weight of 150 g/m² wasimpregnated with a phenol-formaldehyde resin solution to a resin contentof 36% by weight, calculated on dry impregnated paper. The wet paper webwas dried to a moisture content of 7% by weight.

The impregnated paper webs as described in a)-d) above were continuouslyfeed in between the two press bands of a continuous-press in thefollowing order; one paper a) with the side with the smallest particlesoriented outwards, one paper b), one paper c) and three papers d).

The pressing cycle lasted for 20 seconds and the pressure was 35 bar.The laminate was then cut into suitable lengths.

The properties of the manufactured laminate were as follows:

    ______________________________________                                         Abrasion:      13900 revolutions                                             Scratch resistance:                                                                                           across/3 (distance), across/5                 ______________________________________                                                        (real)                                                    

EXAMPLE 7

The procedure according to example 6 was repeated with the differencethat the slurry of melamine-formaldehyde resin in step a) containedaluminium oxide particles to an amount of 5.3% by weight instead of10.6% by weight. The average size of the particles was 1 μm instead of 3μm. The total amount of added aluminium oxide particles was 9+2.7 g/m².

The properties of the manufactured laminate were as follows:

    ______________________________________                                            Abrasion:   13900 revolutions                                             Scratch resistance:                                                                                            across/5 (distance) across/7                 ______________________________________                                                        (real)                                                    

EXAMPLE 8

a) One roll of so-called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 70% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 8 g/m². The particles were ofan average size of 50 μm. The paper web was then continuously dried in aheating oven to a moisture content of 7% by weight. The other side ofthe paper was left untreated and was therefore not coated with any hardparticles. The paper web was cut into sheets of a suitable length.

Step b), c) and d) were repeated according to example 1.

The impregnated paper sheets according to a)-d) above were placedbetween two press plates in the following order; one paper a) with theparticle side oriented downwards, one paper b) with the sprinkled sideoriented outwards, one paper c) and three papers d). The pressing wasconducted in the same way as in example 1.

The properties of the manufactured laminate were as follows:

    ______________________________________                                        Abrasion:      13550 revolutions                                              Scratch resistance:                                                                                           across/31 (distance), across/41               ______________________________________                                                       (real)                                                     

EXAMPLE 9

a) One roll of so-called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 50% by weight, calculated on dryimpregnated paper. The paper web was then dried to a moisture content of7.2% by weight.

One side of the paper was coated with a slurry of a solution ofmelamine-formaldehyde resin containing aluminium oxide particles to anamount of 5.0% by weight. The average size of the particles was 3 μm.

The paper web was then continuously dried in an oven until the moisturecontent in the paper was 8.6% by weight.

The final resin content of the completely impregnated paper was 70% byweight calculated on dry impregnated paper, and the total amount ofadded aluminium oxide particles was 3.3 g/m².

The paper web was cut into sheets of a suitable length.

b) One roll of patterned decor paper of α-cellulose with a surfaceweight of 38 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 50% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 9.5 g/m² by using the sameapparatus as in a) above. The particles were of an average size of 50μm. The paper web was then dried to a moisture content of 6.7% byweight. The paper web was cut into sheets of the same length as in a)above.

c) One roll of monochromatic decor paper with a surface weight of 100g/m² was impregnated with a melamine-formaldehyde resin solution to aresin content of 54% by weight, calculated on dry impregnated paper. Theimpregnated paper web was dried to a moisture content of 6.5% by weight.

The paper web was cut into sheets of the same length as in a) and b)above.

d) One roll of Kraft paper with a surface weight of 170 g/m² wasimpregnated with a phenol-formaldehyde resin solution to a resin contentof 28% by weight, calculated on dry impregnated paper. The wet paper webwas dried to a final moisture content of 7% by weight. The paper web wascut into sheets of the same length as above.

The impregnated paper sheets as described in a)-d) above were placedbetween two press plates in the following order; one paper a) with theparticle coated side oriented outwards, three paper b) with thesprinkled side oriented outwards, one paper c) and three papers d).Together the last mentioned papers, so called base sheets formed a baselater of the laminate which was manufactured by pressing the sheets in aconventional multi-opening press during 80 minutes and at a pressure of85 bar.

The properties of the manufactured laminate were as follows:

    ______________________________________                                          Abrasion:     26100 revoiutions                                             Scratch resistance:                                                                                            across/1 (distance) across/9                 ______________________________________                                                        (real)                                                    

EXAMPLE 10

a) One roll of patterned decor paper of α-cellulose with a surfaceweight of 41 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 41% by weight, calculated on dryimpregnated paper. The paper web was then dried to a moisture content of6.7% by weight. One side of the paper web was then coated with a slurryof melamine-formaldehyde resin containing aluminium oxide particles toan amount of 5% by weight. The particles had an average size of 3 μm.

The paper web was then continuously dried in an oven until the moisturecontent of the paper was 7.4% by weight.

The final resin content of the completely impregnated paper was 63% byweight calculated on dry impregnated paper, and the total amount ofadded aluminium oxide particles was 3.3 g/m².

The paper web was cut into sheets of a suitable length.

b) One roll of patterned decor paper of α-cellulose with a surfaceweight of 41 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 49% by weight, calculated on dryimpregnated paper. The top side of the wet paper web was sprinkled withaluminium oxide particles to an amount of 9.5 g/m². The particles wereof an average size of 50 μm. The paper web was then dried to a moisturecontent of 7% by weight. The paper web was cut into sheets of the samelength as in a) above.

The steps c) and d) according to example 9 were repeated and a laminatewas manufacture in the same way as in example 9.

The impregnated paper sheets as described in a)-d) above were placed inthe following order: one paper a) with the particle coated side orientedoutwards, three papers b) with the sprinkled side oriented outwards, onepaper c) and three papers d).

The properties of the manufactured laminate were as follows:

    ______________________________________                                         Abrasion:      27100 revolutions                                             Scratch resistance:                                                                                           across/5 (distance), across/9                 ______________________________________                                                        (real)                                                    

EXAMPLE 11

a) One roll of so-called overlay paper of α-cellulose with a surfaceweight of 25 g/m² was impregnated with a melamine-formaldehyde resinsolution to a resin content of 50% by weight, calculated on dryimpregnated paper.

The paper web was then continuously dried in a heating oven. Themoisture content in the paper, was after drying 10% by weight.

One side of the paper web, was coated with a slurry of a solution ofmelamine-formaldehyde resin containing aluminium oxide particles to anamount of 5.0% by weight. The average size of the particles was 3 μm.

The paper web was then continuously dried in an oven until the moisturecontent of the paper was 7% by weight.

The final resin content in the completely impregnated paper was 70% byweight calculated on dry impregnated paper, and the total amount ofadded aluminium oxide particles was 3.3 g/m².

The paper web was cut into sheets of a suitable length.

b) One roll of so-called decor paper with a surface weight of 100 g/m²was impregnated with a melamine-formaldehyde resin solution to a resincontent of 46% by weight, calculated on dry impregnated paper. The paperweb was then dried to a moisture content of 4% by weight.

The paper web was cut into sheets of the same length as in a) above.

c) One roll of Kraft paper with a surface weight of 170 g/m² wasimpregnated with a phenol-formaldehyde resin solution to a resin contentof 28% by weight, calculated on dry impregnated paper. The wet paper webwas dried to a moisture content of 7% by weight. The paper web was cutinto sheets of the same length as above.

The impregnated paper sheets as described in a)-c) above were placedbetween two press plates in the following order: one paper a) with theparticle coated side oriented outwards, one paper, b) and three papersc). Together the three last mentioned papers, so called base sheets,formed a base layer of the laminate which was manufactured by pressingof the sheets in a conventional multi-opening press during 80 minutesand at a pressure of 85 bar.

The properties of the manufactured laminate were as follows:

    ______________________________________                                        Abrasion:                         200 revolutions                             Scratch resistance:                                                                                           across/5 (distance), across/9                 ______________________________________                                                        (real)                                                    

What is claimed is:
 1. A process for the manufacture of a decorativethermosetting laminate with an abrasion resistant and a scratchresistant surface layer, said process comprising:providing aresin-impregnated paper web with one side of the web having about 1-15g/m² of hard particles with an average particle size of about 1-15 μmand a second side of the web having about 2-20 g/m² of hard particleswith an average particle size of about 30-90 μm; orienting said paperweb such that said one side having the hard particles of smaller averageparticle size is directed toward a pressing surface; orienting thesecond side of the web so as to face a base layer; and pressing saidpaper web with said pressing surface under heat and pressure for a timesufficient to cure said resin and bond said paper web and said baselayer into a laminate.
 2. A process for the manufacture of a decorativethermosetting laminate with an abrasion resistant and a scratchresistant surface layer, said process comprising:providing a firstresin-impregnated paper web with one side of the web having about 1-15g/m² of hard particles with an average particle size of about 1-15 μm;providing a second resin impregnated paper web with one side of the webhaving about 2-20 g/m² of hard particles with an average particle sizeof about 30-90 μm; orienting said first paper web having the smallerparticles thereon such that said hard particles are directed towards apressing surface; locating said second resin impregnated paper web on aside of said first paper web remote from said pressing surface andadjacent a base layer; subjecting said first and second paper webs andsaid base layer to conditions of heat and pressure from said pressingsurface for a time sufficient to cure said resin and bond said first andsaid second sheets and said base layer into a laminate.
 3. The processaccording to claim 1 wherein said paper web and said base layer aresimultaneously pressed.
 4. The process according to claim 2 wherein saidsubjecting to pressure step is continuous.
 5. The process according toclaim 1 wherein said resin is melamine-formaldehyde resin.
 6. Theprocess according to claim 2 wherein said first and second resin ismelamine-formaldehyde resin.
 7. The process of claim 1 wherein said oneside has hard particles of average particle size of about 1-9 μm.
 8. Theprocess of claim 1 wherein said second side has hard particles ofaverage particle size of about 40-70 μm.
 9. The process according toclaim 1 wherein said base layer comprises a plurality of dry pre-pregsheets impregnated with a resin selected from the group consisting ofphenol-formaldehyde resin and phenol-urea-formaldehyde resin.
 10. Theprocess according to claim 2 wherein said base layer comprises aplurality of dry pre-preg sheets impregnated with a resin selected fromthe group consisting of phenol-formaldehyde resin andphenol-urea-formaldehyde resin.
 11. The process of claim 1 wherein saidbase layer comprises a board material selected from the group consistingof fibre-board and particle board.
 12. The process of claim 2 whereinsaid base layer comprises a board material selected from the groupconsisting of fibre-board and particle board.
 13. The process of claim 1wherein said paper web comprises an overlay paper.
 14. The process ofclaim 1 wherein said paper web comprises a decorative sheet.
 15. Theprocess according to claim 1 wherein said hard particles are selectedfrom the group consisting of silicon dioxide, aluminum oxide, siliconcarbide and mixtures thereof.
 16. The process according to claim 1wherein another hard particle containing sheet is placed between saidpaper web and said base layer prior to said pressing step.
 17. Theprocess according to claim 2 wherein said first resin-impregnated paperweb contains hard particles with an average particle size of about 1-9μm.
 18. The process according to claim 2 wherein said firstresin-impregnated paper web is an overlay sheet.
 19. The processaccording to claim 2 wherein said first resin-impregnated paper web is adecorative sheet.
 20. The process according to claim 2 wherein said sideof said second resin impregnated paper web having the hard particlesthereon is oriented towards said pressing surface.
 21. A process for themanufacture of a decorative thermosetting laminate with an abrasionresistant and scratch resistant surface layer, said laminate comprisinga paper web with a thermosetting resin, said process comprisingimpregnating a continuous paper web with a thermosetting resin, and withthe surface of the paper web wetted with said resin, coating one side ofthe continuous paper with 2-20 g/m² of hard particles with an averageparticle size of about 30-90 μm by means of a device comprising acontainer containing the hard particles and a rotating doctor-roll withan uneven surface placed under the container, whereby the particles areintended to fall down from the container to the doctor-roll and then beevenly distributed over the surface of resin on the paper webcontinuously fed under the doctor-roll, then drying the resin with theparticles coated thereon, coating a second side of the web with athermosetting resin mixture containing 1-15 g/m² of hard particles withan average particle size of about 1-15 μm, drying the resin with theparticles therein, orienting said paper web such that said one sidehaving the hard particles of smaller average particle size is directedtoward a pressing surface, orienting the second side of the web so as toface a base layer; and pressing said paper web with said pressingsurface under heat and pressure for a time sufficient to cure said resinand bond said paper web and said base layer together and form alaminate.
 22. The process of claim 21 wherein the particle coatedimpregnated paper web is cut into sheets prior to said pressing step.23. The process of claim 21 wherein said pressing step is continuous.24. The process of claim 21 wherein another hard particle-coated paperweb is placed between said paper web and said base layer prior to saidpressing step.
 25. The process of claim 21 wherein said decorativethermosetting laminate is a flooring laminate.
 26. A process for themanufacture of a decorative thermosetting laminate with an abrasionresistant and scratch resistant surface layer, said laminate comprisinga paper web with a thermosetting resin, said process comprisingimpregnating a first continuous paper web with a thermosetting resin,and with the surface of the paper web wetted with said resin, coatingone side of the continuous paper with 2-20 g/m² of hard particles withan average particle size of about 30-90 μm by means of a devicecomprising a container containing the hard particles and a rotatingdoctor-roll with an uneven surface placed under the container, wherebythe particles are intended to fall down from the container to thedoctor-roll and then be evenly distributed over the surface of resin onthe paper web continuously fed under the doctor-roll, coating one sideof a second paper web with a thermosetting resin mixture containing 1-15g/m² of hard particles with an average particle size of about 1-15 μm,orienting said second paper web such that said one side having the hardparticles of smaller average particle size is directed toward a pressingsurface, placing said first web between said second web and a base layerto form a composite; and pressing said composite with said pressingsurface under heat and pressure for a time sufficient to cure said resinand bond said first and said second paper web and said base layertogether and form a laminate.
 27. The process of claim 26 wherein theparticle coated impregnated paper web is cut into sheets prior to saidpressing step.
 28. The process of claim 26 wherein said pressing step iscontinuous.
 29. The process of claim 21 wherein said decorativethermosetting laminate is a flooring laminate.